Lincoln-electric IDEALARC DC-655 User Manual

SVM142-ASeptember, 2002Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However,your overall s

Read this entire installation sectionbefore you start installation.SAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Only qualified personnel shouldperform

SVM ERROR REPORTING FORMWe need to know if there are errors in our manuals. We also value any suggestions as toadditional tests or procedures that wo

ELECTRICAL DIAGRAMSG-1 G-1DC 655Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCElectrical Diagrams Section...

G-2ELECTRICAL DIAGRAMSDC 655Wiring Diagram (G3348-1)BRASS305G2G5G4G3G1G64122212341J72G5345AB2GREEN (FRONT VIEW) RECEPTACLE (FRONT VIEW) (FRONT VIEW)77

G-3ELECTRICAL DIAGRAMSDC 655G-3Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

G-4ELECTRICAL DIAGRAMSDC 655Firing Board Schematic (G2792)7-17-98AG2792G-4Return to Section TOC Return to Section TOC Return to Section TOC Return to

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ELECTRICAL DIAGRAMSG-6 G-6DC 655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to

ELECTRICAL DIAGRAMSG-7 G-7DC 655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to

ELECTRICAL DIAGRAMSG-8 G-8DC 655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to

NOTESDC 655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to

INPUT POWER SUPPLY CONNECTIONSA qualified electrician should connect the input powersupply leads.1. Follow all national and local electrical codes.2.

OUTPUT CONNECTIONSELECTRODE AND WORK CABLESUse the shortest possible cable lengths. See Table A.1for recommended cable sizes based on length.The outpu

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TERMINAL STRIPSTerminal strips are available behind the cover panel onthe lower case front to connect wire feeder controlcables that do not have a 14-

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection B-1 Section B-1IDEALARC DC-655TABLE OF CONTENTS- OPERATION

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GENERAL DESCRIPTIONThe DC-655 is an energy efficient constant voltage DCpower source that produces outstanding arc charac-teristics for multiple CV or

1. INPUT POWER ON/OFF SWITCH - This tog-gle switch turns the machine on or off. Putting theswitch in the ON position energizes themachine’s

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSAFETYi iIDEALARC DC-655FOR ENGINEpowered equipment.1.a. Turn the e

3. 42 VAC 10 AMP CIRCUIT BREAKER - Thisbreaker protects the 42 VAC auxiliary circuits locat-ed in the terminal strip and MS-receptacle.4. 14-PI

THERMAL SHUTDOWNThis welder has thermostatic protection from exces-sive duty cycles, overloads, loss of cooling, and highambient temperature. When the

WELDING PERFORMANCELOW INDUCTANCE TERMINALThe inside right Negative (-) terminal is lower chokeinductance and presently is only recommended forwelding

TABLE OF CONTENTS- ACCESSORIES -Accessories...

FIELD INSTALLED OPTIONSK1482-1 Digital Ammeter/Voltmeter Kit - Installseasily to the front control panel and provides digitaldisplay of actual welding

The DC-655 can be used to power any ofthe following Lincoln Wire feeders:SEMI-AUTOMATIC WIRE FEEDERS• DH-10 • LN-9*• LN-10 • LN-9 GMA*• LN-7 GMA* • LN

NOTE: The connection diagram shown in Figure C.1shows the electrode connected for positivepolarity. To change polarity:a. Set the Idealarc DC-655 POW

6. Connect NA-5/-5R wire feeder control jumpers onVoltage Control Board. See NA-5/-5R Operator’sManual.NOTE: The connection diagram shown in Figure C

SEMIAUTOMATIC WIRE FEEDERSCONNECTING THE LN-7 TO THE IDEALARC DC-655 (14-PIN MS RECEPTACLE)1. Set the POWER toggle switch to the OFF (0) posi-tion.2.

CONNECTING THE LN-7 TO THEIDEALARC DC-655 (TERMINAL STRIP)1. Set the Idealarc DC-655 POWER toggle switch tothe OFF (0) position.2. Disconnect main AC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSAFETYii iiIDEALARC DC-655ARC RAYS can burn.4.a. Use a shield with

CONNECTING THE LN-8 OR LN-9 TO THEIDEALARC DC-655 (TERMINAL STRIP)1. Set the Idealarc DC-655 POWER toggle switch tothe OFF (0) position.2. Disconnect

CONNECTING THE LN-8 OR LN-9 TO THEIDEALARC DC-655 (14-PIN MS RECEPTACLE)1. Set the POWER toggle switch to the OFF (0) posi-tion.2. Disconnect main AC

NOTESIDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC R

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection D-1 Section D-1IDEALARC DC-655TABLE OF CONTENTS-MAINTENANCE

SAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Only qualified personnel should per-form this maintenance.• Turn the input power OFF at the disconnect s

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NOTESIDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC R

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection E-1 Section E-1IDEALARC DC-655Theory of Operation ...

GENERAL DESCRIPTIONThe DC-655 is a three-phase, SCR controlled DCpower source. It is capable of either constant currentor constant voltage output. I

CONTROL BOARD, FIRING BOARD,SNUBBER/FAN, BOARD AND RECTIFICATIONThe “neutrals” of the welding secondary windings inthe main transformer are connected

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSAFETYiii iiiIDEALARC DC-655FOR ELECTRICALLYpowered equipment.8.a.

THEORY OF OPERATIONE-4 E-4IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC R

SCR OPERATIONA silicon controlled rectifier (SCR) is a three-terminaldevice used to control rather large currents to a load.An SCR acts very much like

NOTESIDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC R

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection F-1 Section F-1IDEALARC DC-655Troubleshooting & Repair

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TROUBLESHOOTING & REPAIRF-3 F-3IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSAFETYiv ivIDEALARC DC-655PRÉCAUTIONS DE SÛRETÉPour votre propre pr

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TROUBLESHOOTING & REPAIRF-9 F-9IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Mas

TROUBLESHOOTING & REPAIRF-10 F-10IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-11 F-11IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-12 F-12IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

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4. Check for the presence of 42 VAC at the ter-minal strip ( #2 to #41). See the SimplifiedTrigger Diagram.5. If 42 VAC is not present at the termi

9. Check continuity (zero ohms) from lead #41(plug P15 pin-10) to plug J5-pin 1 at the fir-ing board. See the Simplified TriggerDiagram and Figure F.

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MASTER TABLE OF CONTENTS FOR ALL SECTIONSv vIDEALARC DC-655PageSafety...

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7. Connect a jumper wire from pin C (lead #2)to pin D (lead #4) at the 14-pin receptacle.See Figure F.5. (Or put the Output TerminalSwitch in the ON

12. Test for 9.5 VDC to 11.0 VDC betweenleads #231 and #215 on the firing board.Make sure the Mode Switch (SW2) is in aconstant voltage (CV) position.

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCTABLE OF CONTENTS- INSTALLATION SECTION -Section A-1 Section A-1IDE

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TROUBLESHOOTING & REPAIRF-29 F-29IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-30 F-30IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

F-31 F-31IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master T

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TEST FOR CONTACT CONTINUITY1. Disconnect the main input supply power tothe DC-655 machine.2. Locate, label and remove the three leadsconnected to the

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6. If a high or infinite resistance is indicated forboth steps #4 and #5, SCR1 is not shorted.7. If a low resistance is indicated in either steps#4 or

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4. Construct the circuit shown in Figure F.17.One 6-volt lantern battery can be used. Setthe voltmeter scale low, at approximately 0-5 volts or 0-10

TROUBLESHOOTING & REPAIRF-41 F-41IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-42 F-42IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

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TROUBLESHOOTING & REPAIRF-45 F-45IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

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INSTALLATIONF-48 F-48IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return

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TROUBLESHOOTING & REPAIRF-54 F-54IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-55 F-55IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-56 F-56IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M

TROUBLESHOOTING & REPAIRF-57 F-57IDEALARC DC-655Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to M